Wind Energy. Electro-technical solutions for wind energy systems. Wind of Change

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1 Wind Energy Electro-technical solutions for wind energy systems Wind of Change

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3 Renewable Energy Ready for wind. Renewable energy on the rise. The utilization of renewable energy, especially wind power, has enormous growth potential coupled with a high degree of acceptance. This industry is one of the economic sectors which looks forward to a positive future. As far as electrical connectivity is concerned, safe and practical solutions are more sought-after than ever. The industry is an ideal application area for pluggable electrical installation, which Wieland offers as part of its broad product spectrum not just for wind energy, but also for solar energy, as well as other environmentally conscious technologies. Greater efficiency through modularity The return on investment of an installation depends on a range of factors: the correct location, the technology being deployed, and effi cient construction. The fact is: the more pre-fabrication is carried out, the lower the installed costs become both in the construction of the overall system as well as in the electrical installation. This is where Wieland with its pluggable systems can improve your return on investment. Reducing operational downtimes and interruptions Investment in a wind turbine is only profi table when it operates without interruption and with as little maintenance as possible. The modularity and reliability of Wieland systems make a signifi cant contribution to these goals. Installation times are reduced by up to 70%, on-site wiring errors are eliminated, and maintenance downtimes are reduced to a minimum. The future lies in pluggable technology. Global installed wind capacity Graphic: Global Wind Statistics2011, GWEC The use of wind power to generate electricity has achieved extreme growth in recent years, as statistics impressively demonstrate. There is no end in sight to this positive trend in fact, quite the opposite is true. In Germany, the portion of wind energy is set to increase from 6.5% to over 25% by the year In the United States, the RES targets 25% by

4 Knowing which way the wind blows. Wieland Electric competence and expertise in green energy technology. Wieland views itself as a reliable partner in the fi eld of electrical installation. A company offering a vast number of components meeting the highest quality standards, including a modular system with a decisively unifying characteristic: that it is pluggable. At the same time, the system is continually growing and improving. Its reliability and fl exibility make it a sound choice for virtually any application, including both fi xed installations, as well as those requiring future modifi cations. Relevant for all applications The Wieland system is ideally suited for wind turbine applications. It provides solutions and components which cover all relevant tasks: in electrical installation, as well as in automation tasks such as controlling, adjusting and safety monitoring. Partnership is extremely important to us No customer requirement goes unfulfi lled, thanks to more than 30 years of experience in facility management and expertise in industrial manufacturing processes. The continuous optimization of products and process makes a time saving of 70% and a cost reduction of 30% possible. Wieland is continually developing its pluggable technology principle - for the renewable energy sector, for example. Wieland offers solutions and components not only for wind energy systems, but also for photovoltaic systems. For decades, Wieland has been working effectively on plug-and-play solutions, both in electrical installation and in automation technology. A broad portfolio of components makes it possible to achieve the highest level of flexibility. 4

5 Wieland Competence Whether offshore or onshore, trouble-free operation of wind turbines determines whether the investment ultimately achieves profitability. Wieland provides the best possible foundation to help achieve this. 5

6 6 An ideal way to achieve decentralized power distribution is to use the podiscon energy bus. Pluggable distribution taps, which can be installed wherever they are needed, offer the utmost flexibility thanks to insulation displacement contacts.

7 Plug & Play Fresh wind. Pluggable means maximum efficiency. In the field of decentralized power distribution, Wieland really shows what it can do. The gesis IP+ plug connector system, the podis fl at cable system and the revos heavy-duty industrial connectors make organized, space-saving cable management possible, e.g. in electrically connecting the gearbox, or lighting, or control cabinets on the ground. Additionally, the pluggability of modules is the key principle behind devices such as relays that are used for switching and isolation. All components are designed to allow them to be connected in the shortest possible time and replaced quickly if required. Designed for tough conditions Vibration and corrosion are ever present in wind energy installations. For this reason, Wieland components are designed and manufactured to ensure that they operate with the utmost reliability in even the toughest environments. gesis IP+ shows the way: Simply install pre-fabricated connector and cable assemblies and the connection is complete, while also maintaining a touch-safe connection. Disconnecting under load is also possible. Wieland offers a comprehensive value-add service; its products include pre-fabricated DIN rail terminal block assemblies that help to reduce production times while minimizing logistical effort. 7

8 Lightning and overvoltage protection Using wietap, the danger of a service interruption due to lightning strikes and overvoltages is reduced significantly, if not eliminated entirely. 8

9 Play it safe Controlling, adjusting, monitoring. Safely and standard compliant. Safe processes are a decisive factor in securing the profi tability of wind turbines. Even in rough climatic conditions and extreme temperature fl uctuations, the system must operate reliably. Just as importantly, protection against lightning strikes is of the utmost priority. The procedures governing the tracking movement in a nacelle are no different. They must be managed in such a way as to eliminate potential hazards, both to man and machine. The safety products from Wieland are a perfectly reliable fi t. All relevant standards are fulfilled Wieland solutions are designed to comply with the stringent safety requirements thanks to a robust construction which accounts for tough environmental conditions and to the fulfi llment of all relevant standards. Play it safe The nacelle of a wind turbine will face the most diverse potential hazards, and must be protected by a system of reliable control and monitoring. Wieland s safety program performs reliably here. bytd h 9

10 Finger on the pulse. Perfect solutions for wind turbines. Wieland offers complete solutions and components for wind turbines both for electrical installation in towers and for all automation applications found in the nacelle. One system many possibilities Wieland components are built upon a modular concept. Precisely designed to work together, the modules can be combined in individual installation topologies. In this way, the Wieland system is limitless. True to the motto Perfect solutions with our fi nger permanently on the pulse. revos heavy duty industrial connectors safety modular safety systems interface power supplies relays lightning and overvoltage protection wienet VPN industrial router wiecon PC board connectors and terminal blocks fasis / selos DIN rail terminal blocks podis CON fl at cable power bus gesis IP+ pluggable installation from IP 65 to IP 68 gesis CON Everything is pluggable! 1 revos 2 safety 3 interface 4 wienet Decentralized power distribution, reliable lightning and overvoltage protection, comprehensive relay technology, pluggable electrical installation just some of the wind turbine applications for which Wieland offers highly developed solutions. 10

11 Wind power Wieland applications in the nacelle Wieland applications in the tower Wieland applications in the base wiecon 6 selos /fasis 7 podis CON 8 gesis IP+ 11

12 12 podis is a modular energy bus system for decentralized energy distribution and simplifies planning procurement installation and maintenance of wind energy installations.

13 podis Field of application: Tower. podis Benefits for the tower builder: One standard tower for all customers / regions Only 1 order number instead of 100 Create variants in last work pass 70 % reduction in installation time Benefits for the system manufacturer Short delivery time for towers Higher flexibility / fewer international variants Tower fittings easily adapted Benefits for system operator / service Maintenance-free lights Central UPS with only one battery Standardized, uniform non-glare and flicker-free illumination Faster, toolless exchange in case of failure Full light power immediately, even at low temperatures 13

14 Connect without stripping wires With podis, time-consuming cutting and stripping are a thing of the past. The insulation-penetrating contacts provide quick, safe and trouble-free installation. 14

15 podis Field of application: Tower. podis flat cables. Hardly any other industry places such demanding requirements on the fl exibility and availability of system technology as wind power. Wind energy systems must be installed and commissioned within extremely short time frames. System availability is often contractually guaranteed, and will have an infl uence on the profi tability of the entire installation. The energy bus solutions from Wieland fully prove their worth here. Combining the uncut podis fl at cable bus with the podis CON functional modules, new installations can be completed in next to no time. Flexible and maintenance-friendly podis delivers the utmost fl exibility inside the tower. Functional modules terminated simply and securely on the power bus cable guarantee maintenancefriendly installation of lighting fi xtures and heavy-duty power receptacles. Cover all international norms / customer requirements with one tower projection 8 article numbers for one tower installation, with only one order number 70 % time savings for tower electrical installation Connection module Schuko power receptacle Extremely flexible The flat cable feature makes it possible to install drops wherever required. This allows for the utmost flexibility in tower installations. CEE Heavy-duty power receptacle LED-Luminaire 15

16 Plug & Play With the installation system gesis IP+, factory terminated cable assemblies and junction boxes are connected to one another on site, saving both time and money. The high protection class IP66/IP68 facilitates fast installation of the illumination in outdoor applications such as lattice towers or cranes. 16

17 gesis IP+ gesis IP+ pluggable round cable power bus Simply plug it. With the gesis IP+ installation system, completely new possibilities arise. Entire system sub-assemblies can be factory terminated and tested, independent of their installation destination. Once on site, the individual modules simply need to be plugged together. This saves time during installation, reduces wiring errors, and improves safety. With gesis IP+, device installation is made simply pluggable. By integrating bulkhead mount connectors into the device, an electrical gateway is established, and electrical devices can be connected simply and safely to the gesis IP+ installation system. The system is so versatile that even unexpected modifi cations can be completed without problems. An additional advantage is a consistent and standardized quality of installation. Maintenance and repair without interruption to turbine operation are made possible, despite the diffi cult working conditions in the tower. Faulty devices can simply be replaced without service interruption. Installation system IP gesis IP+ Areas of application: Tower lighting Power receptacles for maintenance Distribution box Features: Installation according to the Plug & Play principle Improved cable management Complete factory terminated installation kits for each tower Integrated lock-outs and strain reliefs 15 uniquely coded plug connections Cables and receptacles available for all countries worldwide High degree of protection IP65, IP66, IP67, IP68 (3 m, 2 hr) 17

18 1 Hub controller revos BASIC 690V 2 Gear box revos FLEX 18

19 revos revos heavy-duty industrial connectors Reliable Connections. Inside the nacelle there are many automation components which need to be electrically connected to each other. Drives; distributed control panels; the electrical connection of the gear box; lighting or the connection to the control panel on the ground, as well as the control panel in the hub controller. The various components are in constant interactive connection with one another, in order to control the function of the entire system. Thanks to their design, which makes them perfect for the rough operating conditions within a wind turbine (i.e. vibration, corrosive conditions), revos industrial connectors are capable of guaranteeing the reliable connection of electrical signals. Areas of application: Connection of drives Pitch control Lighting Aviation warning Hub control Yaw control Features: Maintenance-friendly Quick and error-free installation Easily modified IP 65 degree of protection Aviation warnings revos FLEX 3 Yaw control 4 Hydraulic pumps revos FLEX COMPACT 1M revos MINI 19

20 1 Plug & Play 2 Spring clamp technology fasis CON fasis 20

21 selos / fasis selos, fasis DIN rail terminal blocks Secure and durable. Wieland wind turbine components are versatile and durable. Whether as terminations for the generator, signal distribution of the control system, or measurement of current or voltage, DIN rail terminal blocks are standard connection devices for all facets of a wind turbine. With the selos and fasis ranges of DIN rail terminal blocks, Wieland offers solutions for the most diverse connection points in a wind turbine. fasis CON Plug & Play in the control cabinet The electrical connection technology used in wind turbines is based on modular wiring concepts covering a multitude of functions. With the fasis CON DIN rail terminal block system, prefabricated terminal block assemblies and wire harnesses can be installed on site with this plug-and-play system. both signal transmission in 24 V sensor circuits and for servomotor power circuits. fasis WKFN Tension spring and Push In connection Robust, high-capacity DIN rail terminal blocks with vibration-proof spring clamp connection technology for all areas of electrical wiring. selos POWER LINE High current terminals High current terminals are available in hybrid design with stud and rising cage connections or as simple stud connection for conductors up to 240 mm 2 and a maximum current of 415 A. selos WKN Screw technology Measuring disconnect blocks for safe current and voltage transformer measuring data. fasis CON features a vibration-proof spring clamp connection that guarantees contact security in all climatic and environmental conditions, thereby minimizing maintenance. Due to its high-capacity contacts of up to 32 A, this system is suitable for 3 High current terminals 4 Screw technology selos POWER LINE selos WKN 21

22 Safety functions: 1 Safety sensors Drive shaft speed monitoring with a speed monitoring device sensor PRO Emergency mode to reduce rotor speed End position monitoring of rotor blades Pressure monitoring of hydraulic system Temperature monitoring of hydraulic oil Fill level monitoring of hydraulic and lubricant system Emergency stop Additional safety circuits Monitoring safety functions is crucial for the safe operation of a wind power system. 22

23 safety safety Safety components Safety at all times. The various potential hazards in the nacelle and at the base of the wind turbine can be eliminated by reliable monitoring and control. For example, movements which endanger maintenance personnel can be eliminated by shutting down the active equipment safely and quickly. Areas of application: Standstill monitoring Emergency stop Safety relays Various sensors are used in the monitoring process (e.g. emergency stop buttons, initiators, rotary encoders and safety relays), the signals of which must be precisely processed. Within the scope of its safety product line-up, Wieland offers safety relay devices for all standard functions, as well as manually adjustable or openly programmable modular safety solutions, which can be connected to all standard sensors - everything you need for the protection of man and machines. Features: Safety relay devices for all standard functions Modular and parameterizable safety control Modular compact safety PLC Spring-clamp or screw terminals (fi xed or pluggable) Slim design (22.5 mm modules) Temperature range from 25 C to +55 C 4 Compact safety PLC samos PRO 2 Universal safety relays 3 Modular safety control safe RELAY samos 23

24 1 Power supplies 2 DC UPS module 3 Lightning and overvoltage protection wipos wipos wietap 24

25 interface interface Electronic components Ready for anything. Wherever current fl ows and signals are processed, the interface products from Wieland Electric display their unique strength. With its broad range of relays, power supplies and overvoltage protection units, as well as discrete interface and analog modules, every wind turbine can be advantageously equipped. wipos Power supplies A 24 V control voltage can be generated using the robust wipos P1. The devices are designed and approved worldwide for a temperature range from 25 C to +70 C. wipos DC UPS module Buffering the 24 V DC supply up to 30 A. Connection of standard lead batteries in range from 2 to 12 Ah. An integrated battery test and a temperature range from 40 C to +70 C round out this product. wietap Lightning and overvoltage protection Lightning strikes on wind turbines are common, due to their exposed installation sites. With lightning and overvoltage protection modules from Wieland, a complete protective system can be created. The devices fulfi ll the most extreme demands made of their current carrying capability. The modular design feature enables quick replacement of the electronic modules, and meets the highest shock and vibration impact requirements in operation. flare MOVE Pluggable coupling relays Various coupling functions can be carried out by the broad range of products in the flare MOVE series. Pluggable coupling relays are also available with high shock and vibration impact certifi cation in various designs, and are ideally suited to the demands of a wind turbine. flare CONTROL Measuring and monitoring relays Whether voltage, current, phase or temperature monitoring: Individual monitoring functions can be carried out both reliably and independently using Wieland s measuring and monitoring relays. cores Analog isolation amplifier Clean galvanic isolation from control signatures can be very easily and fl exibly guaranteed through the cores product series. 4 Pluggable coupling relays 5 Measuring and monitoring relays flare MOVE flare CONTROL 6 Analog isolation amplifi er cores 25

26 Complete remote maintenance solution from a single source The requirements for remote maintenance are broadly diversifi ed: data security, high bandwidths, access control and above all, simple operability without special IT skills. The combination of VPN server portal Wie-Service24 and the wienet industrial routers fulfill precisely this requirement. Use of the Internet makes it possible to send even greater data volumes with high security. The VPN confi gurations necessary to do so are automatically created by the VPN server. In the end, only one confi guration file must be transmitted to the respective router and everything goes from there. 26

27 wienet wienet VPN Industrial Router unlimited M2M communication Wie-Service24 LAN-TO-LAN Machines or plants Technician Technician Mobile router Machines or plants Wie-Service24 VPN service portal All machines online! SMS information We will extend your network line, no matter where With the Wieland solution, you directly access the terminal device via 1:1 NAT. It is as though you were directly connected with your terminal device via cable. The router hardware needed matches your requirements. Select between plastic or metal housing. If your system has an Internet connection, the LAN-to-LAN router is the right choice. If you do not have any Internet, cannot go through a customer network or generally want to be non-localized, then select one of the mobile radio routers. GSM, GPRS, EDGE, UMTS, HSDPA, HSUPA, HSPA+ and LTE are supported. As an option, the devices are also available with additional interface modules. Variants with RS-232, RS-422/485, digital and analog in- and outputs, M-Bus and additional Ethernet ports are available. Advantages Security by VPN Automatic generation of router configuration Only outgoing connections towards Wie-Service24 are necessary No changes inside the local network is necessary Interconnection of complete networks, without additional routing configuration Small need for coordination with IT department and easy commissioning More information is available from our technical support: Telefon Telefax wie-service24@wieland-electric.com 27

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29 wiecon wiecon PC board terminal blocks / PC board connectors Secure connections. wiecon is ideally suited to applications in controlling a wind turbine: with spring clamp or screw connections, pluggable or direct mount versions. Clearly marked terminations, easy to wire connections, and an integrated test point guarantee service-friendly usage and reliable connections. wiecon PC board terminal blocks and PC board connectors also score bonus points, since they are compliant with all relevant standards, and their excellent connection technology withstands in the long term - the infl uences of vibration. Areas of application: Frequency converter Electronic controls Features: Various termination technologies, in both terminal block and pluggable versions. Secured against shock and vibration impact Integrated test points PC board terminal blocks / PC board connectors wiecon 29

30 Support Hotline advice Additional information Technical support Automation technology: Safety technology safety Phone: Remote power distribution podis Phone: interface: Power supply, industrial Ethernet switches, timer relays, measuring and monitoring relays, coupling relays, analog modules, remote I/O, surge protection, passive interfaces Phone: DIN rail terminal blocks fasis, selos Phone: Industrial multipole connectors revos Phone: PCB terminals and connectors wiecon Appliance terminals, european terminal strips, housings for electronic components Phone: Fax: Technical Support Building services engineering: System connectors for building installation gesis CON, gesis RAN, gesis ELECTRONIC Phone: DIN rail terminal blocks fasis BIT, selos BIT Phone: Fax: Technical Support Photovoltaics/solar technology: Photovoltaics gesis SOLAR Phone: Fax: Sales service: To contact our sales department regarding availability, delivery schedules, and pricing please call Phone: General information and news: Visit our ecat at Stefan Kadur, Industrial Manager, Wind Power 30

31 contacts are green Our subsidiaries... and the addresses of our representations worldwide are available at: USA Wieland Electric Inc. 49 International Road Burgaw, N.C Phone Fax CANADA Wieland Electric Inc Brighton Road Oakville, Ontario L6H 6C9 Phone Fax GREAT BRITAIN Wieland Electric Ltd. Riverside Business Centre, Walnut Tree Close GB-Guildford /Surrey GU1 4UG Phone Fax FRANCE Wieland Electric SARL. Le Céramê Hall 6 47, avenue des Genottes CS Cergy-Pontoise Cedex Phone Fax infos@wieland-electric.fr SPAIN Wieland Electric S.L. C/ Maria Auxiliadora 2 bajos Barcelona Phone Fax ventas@wieland-electric.com ITALY Wieland Electric S.r.l. Via Edison, Settimo Milanese Phone Fax info@wieland-electric.it POLAND Wieland Electric Sp. Zo.o. Św. Antoniego Swadzim Phone Fax office@wieland-electric.pl DENMARK Wieland Electric A/S Vallørækken 26 DK-4600 Køge Phone Fax sales@wieland-electric.dk CHINA Wieland Electric Trading Unit 2703 International Soho City 889 Renmin Rd., Huang Pu District PRC- Shanghai Phone Fax info-shanghai@wieland-electric.cn CZECH REPUBLIC (Production) Wieland Electric s.r.o. Nadražni Sokolov Phone Fax Informational material for ordering and for downloading from our websites Subject to technical modifications! gesis, podis, samos are registered trademarks of Wieland Electric GmbH 31

32 Headquarters: Wieland Electric GmbH Brennerstraße Bamberg, Germany Sales and Marketing Center: Wieland Electric GmbH Benzstraße Bamberg, Germany Phone Fax info@wieland-electric.com Industrial technology Solutions for the control cabinet DIN rail terminal blocks Screw, tension spring or push-in connection technology Wire cross sections up to 240 mm 2 Numerous special functions Software solutions interfacing to CAE systems Safety Safe signal acquisition Safety switching devices Modular safety modules Compact safety controllers Applicative consultancy and training Network engineering and fi eldbus systems Remote maintenance via VPN industrial router and VPN service portal Industrial Ethernet switches PLC and I/O systems, standard and increased environmental conditions Interface Power supply units Overvoltage protection Coupling relays, semiconductor switches Timer relays, measuring and monitoring relays Analog coupling and converter modules Passive interfaces Solutions for field applications Decentralized installation and automation technology Electrical installation for wind tower Fieldbus interfaces and motor starters Connectors for industrial applications Rectangular and round connectors Aluminum or plastic housings Degree of protection up to IP 68 Current-carrying capacity up to 100 A Connectors for hazardous areas Modular, application-specifi c technology PC board terminals and connectors Screw or spring clamp connection technology Spacings: 3.5 mm to mm Refl ow or wave soldering process Building and installation technology Building installation systems Main power supply connectors IP 20/IP IP 68 Bus connectors Low-voltage connectors Power distribution system with fl at cables Distribution systems Bus systems in KNX, LON and radio technology DIN rail terminal blocks for electrical installations Overvoltage protection C 10/12